A related concept to waste walks, the subject of our previous few posts, is the “Ohno Circle.”
Taiichi Ohno is credited for much of the thinking behind the Toyota
Production System, and he invented a novel method of making improvements. He would go to draw a chalk circle on the floor, and stand in it. He would stand for hours, watching and thinking about what he was seeing. He would look for what was getting in the way of people creating value and he would study the situation to determine what was causing it. This gave him the insight he needed to make lasting improvements.
Ohno’s approach is different from simply visiting “gemba” or touring the line, as it goes beyond “looking” to “watching.” Taking the time to actually watch work being done can pay big dividends, and often helps well-intentioned people avoid “learning too little and assuming too much.”
In fact, many CI leaders have confessed, after-the-fact, that, if they had simply stood in one place long enough to watch carefully, they would have quickly seen the true root causes of many problems that took weeks to solve.
Continuing the theme of “waste walks,” there are several fundamental guidelines that should be followed in order to optimize the value and outcomes.
Here are some best practices for implementing Waste Walks (or “going to gemba“) that have proved successful in organizations and that have brought-about break-through results:
- Communicate before starting. Begin by breaking the ice with the people in the work area so they know what is happening and why; make it clear that this is not a fault-finding mission, that there is amnesty, and that the Waste Walk is an effort to “help, not to shoot the wounded.”
- Communicate with the gemba team. Establish ground rules, making sure to describe the theme or the forms of waste the team will be targeting, along with any other expectations relative to objectives people issues, desired outcomes, and so on.
- Describe the start and end points of what you want to observe and study.
- Conduct the Waste Walk and maintain communication protocols throughout; remind the team that as they interact with and pose questions to those doing the work, they must listen carefully to the answers.
- Reconvene in a meeting room afterward to record ideas, consider what the team has learned, set priorities, and move into action! Sometimes it gets harder as the team disperses, so be sure to maintain communication and measure progress after-the-fact.
- Be inquisitive…curious…
- Make Waste Walks a regular part of people’s work; they should not happen once in a blue moon
Finally, if there is an over-arching theme or mantra associated with an effective waste walk, it is NOT “Don’t just stand there; do something!”
Conversely, the best over-arching mantra is, “Don’t just do something; stand there and learn!”